Method and apparatus for making a record carrier for automatic embroidery sewing machine

ABSTRACT

Method and apparatus for making a record carrier for an automatic embroidery sewing machine to detect amounts of longitudinal, lateral and angular movements of a cloth frame moving device, amplitude detection of the machine needle and start-stop instructions for the machine, with rotary pulse generators that generate pulses for the various movements. A magnetic record carrier records the pulse trains taken as outputs of the pulse generators.

United States Patent 1 [111 3,750,186

Sakamoto 1 July 31, 1973 [54] METHOD AND APPARATUS FOR MAKING 2,996,3488/1961 Rosenberg 346/33 MC A RECORD CARRIER FOR AUTOMATIC 3,072,8331/1963 Kerr et a1. 346/33 MC X 3,251,039 5/1966 Dupy et al. 346/33 MC XEMBROIDERY SEWING MACHINE 3,459,145 8/1969 Ramsey et a1. 1l2/12l.ll

lsamu Sakamoto, Nishinomiya, Japan Inventor:

Konan Camera Laboratory Company Limited, Kobe City, Japan Filed: May 11,1970 Appl. No.: 36,111

Assignee:

U.S. Cl 346/1, 112/102, 1l2/121.12, 318/568, 346/33 MC Int. Cl. G0ldD05b 21/00 Field of Search 346/33 MC, 1; ll2/1 2l.1l, 121.12, 102, 103;318/568, 576, 577, 578; 340/347 P; 235/l5l.11; 340/l74.1 K; 33/1 C, l M,l N

References Cited UNITED STATES PATENTS 12/1959 Neergaard 346/33 MC XPrimary ExaminerJoseph W. Hartary AnorneyOtto John Munz [57] ABSTRACTMethod and apparatus for making a record carrier for an automaticembroidery sewing machine to detect amounts of longitudinal, lateral andangular movements of a cloth frame moving device, amplitude detection ofthe machine needle and start-stop instructions for the machine, withrotary pulse generators that generate pulses for the various movements.A magnetic record carrier records the pulse trains taken as outputs ofthe pulse generators.

2 Claims, 10Drawing Figures SHEEI 1 0F 4 FIG. 2

INVENTOR ISAMU SAKAMOTO ATTORNEY PATENIEBJUL31 ms PIP/0A AA? PATENIEUJULBI ms SHEEI 2 (IF 4 INVENTOR ISAMU SAKAMOTO ATTORNEY co E? L INVENTORISAMU SAKAMOTO BY MI ATTORNEY METHOD AND APPARATUS FOR MAKING A RECORDCARRIER FOR AUTOMATIC EMBROIDERY SEWING MACHINE This invention relatesto a method of making a record carrier for an automatic embroideringsewing machine and a apparatus including cloth frame moving device foran automatic embroidering sewing machine.

An object of the present invention is to provide a method of easilyrecording the program the longitudinal and lateral movements androtation of a cloth frame and the lateral amplitude of a machine needlewithin a short period of time for use in an embroidering sewing machine.

Another object of the present invention is to provide an automaticembroidery sewing machine wherein a magnetic tape in which the movementrecords are made is fed to a reproducing machine for reproducing therecords whereby exactly the same embroidery design as the originalembroidery design is reproduced.

A further object of the present invention is to provide a cloth framemoving device in which the amounts of longitudinal, lateral rotationalmovements and the lateral amplitude of the needle are made with pulsemotors.

In the accompanying drawings:

FIG. I is a plan view schematically showing a conventional device inaccordance with the prior art;

FIG. 2 is a view showing various embroidered designs;

FIG. 3 is a plan view showing a cloth frame moving device for anembroidering sewing machine according to the present invention;

FIG. 4 is a plan view of another embodiment of the device shown in FIG.3

FIG. 5 is a magnified an enlarged perspective view of a particular partof the device of FIG. 4

FIG. 6 is a side view showing an example of a rotary pulse generator; V

FIG. 7 is a graph diagram showing an output curve of a rotary pulsegenerator;

FIG. 8 is a block diagram showing the process of the wave form treatmentshown in FIG. 7;

FIG. 9 is a diagrammatic representation of showing an embodiment of a arecording device; and

FIG. 10 is a diagrammatic representation of an embodiment of areproducing device.

The present invention provides an automatic embroidering sewing machinein which a record carrier such as a punched tape, a magnetic sheet ortape on which records are made is held so that embroidering may beautomatically accomplished. The record carrier is made by thehereinbelow described method.

As shown in FIG. 1, a prior art device comprises: two shafts l and 1'that are parallel-to each other are position a proper distance-from eachotherybelts 2 and 2' are hungon the respective ends of the shafts; and atracer 4 supported on aguide'bar 3 is mounted between said belts-2 and2'. When two handles 6 and 6' are separately operated, the tracer 4traces a figure or design that is-described on a pattern 5 and themovements of pointer of the tracer are determined being divided into Xand Y components.

Atthe'same time, computing mechanisms 7' in a record making device 7that are connected with the handles 6 and 6' compute the X and Ycomponents.

Then, if a pedal 8 is operated to a stopping position of the tracer 4, arecording mechanism 7"records the above mentioned computed result in therecord carrier 9. The respective points traced by the tracer are thepoints at which the needle of the sewing machine falls when they arereproduced. The tracer 4 makes point movements with the handles 6 and 6.Therefore, even if, for example, a figure of a leaf design is recordedand reproduced as in A in FIG. 2, the design will only be an outline ofthe same.

There is considerable time and labor required to make an embroidery inwhich the space between the veins is filled as in A in FIG. 2. Thisfilling provides a three-dimensional effect a swelling appearance andthus, a pleasing vision effect results. Further, it is to be noted thatthe moving device that includes the shafts l and 1', belt 2 and 2 andthe freely moving tracer on guide bar 3, cannot be rotated in itself. Inorder to trace a flower design and radial design as shown in B and C,respectively, in FIG. 2. much skill and time a technician familiar withthe art required. It is only with considerable difficult that the insidespaces are filled as in B and Cin FIG. 2.

The present invention relates to a method of making a record carrier andto apparatus a cloth frame moving device. The invention is characterizedby, in the making of a record carrier if the initial sheet is made bythe same operation as that of the ordinary embroidering operation. Thatis, the ordinary operation peformed by a skilled operator having a hightechnical skill of a zigzag embroidering sewing machine that is providedwith a cloth frame moving device which can not only move but also rotatethe X and Y components, and produce the program of the X and Ycomponents and rotation of the cloth frame, the lateral amplitude of theneedle and the starting and stopping of the sewing machine.

The various movements can easily be recorded within a short time frameby the use of rotary pulse generators. In producing embroidery designs,if the above mentioned record carrier is fed to a reproducing sewingmachine, even an operator having little or no knowledge and technique ofembroidering can reproduce the embroidery design perfectly. Thus, animproved efficiency and a higher production will result.

Broadly, in accordance with the present invention, the method relates torapidly making a record carrier wherein an operator sews a selectedembroidery design with an automatic embroidering sewing machine having asewing needle and comprises the steps as follows:

moving a cloth frame assembly having a stretched object or workpiecesupported on the assembly and moving short distances in X-axis andY-axis directions and I in an angular rotary direction to an operativeposition;

moving the needle in a Y-axis direction to an operative position;

detecting the distance amounts of the various movements of therespective cloth frame assembly and needle by the use of individualrotary pulsegenerators;

the pulse generators generating output pulses representing the distanceamounts in response to the operative position of the workpiece relativeto the operative position of the needle;

recording the output pulses as master record trains in a magnetic recordcarrier; and

playing back .the recorded-record carrier into said cloth frame assemblyto automatically reproduce the selected embroidery desigmwherebythereafter an unskilled operator may monitor the operation of theautomatic embroidery sewing machine to produce the selected embroiderydesign.

More specifically, the cloth frame moving device to be fitted in therecording embroidering sewing machine in working the method of thepresent invention is explained with reference to FIG. 3. There isillustrated a moving device in which two rails 11 and 11 are mounted ontwo rails 10 and 10' to form a rectangular structure. The rails 10, 10are separated from each other by a predetermined distance to each other.A carriage 12 is slidably mounted to ride on the two rails 11 and 11'.Thus, the rails 11, 11 and 10, 10 form rectangular coordinates formrectangular coordinates for the X and Y components respectively.

A cloth frame 13 in the form of a ring or a circular member isoperatively supported by a gear arrangement in said carriage l2 and isrotatable with mounted on supporting wheels 14, 14' and 14" that areprovided in three positions that equally divide the outer periphery ofsaid frame. Therefore, in making an embroidery design, the cloth framecan not only rotate but also freely move reciprocate within therectangular structure by virtue of the gear arrangement through therails ten and 10' and rails 11 and 11. Thus, all of three kinds ofmovements are recorded in the record carrier. The movement of the Xcomponent is detected by a rotary pulse generator 15. That of the Ycomponent is detected by a rotary pulse generator 16. The movement forthe rotation of the rotary cloth frame is detected by a rotary pulsegenerator 17.

FIGS. 4 and show another embodiment of the present invention wherein asimilar cloth frame moving device has an annular frame 18 in the form ofa large ring that is supported so as to be easily rotatable by hand bymeans of supporting wheels 19, 19' and 19" that are provided in threepositions equally dividing the outer periphery of said frame. A smallring-shaped frame catcd within this annular frame 18 is a cloth frame 20in which embroidering is to be made. An arm rod 21 fixed to the outerperiphery of the cloth frame 20 is slidably inserted in a blockshapedsupporter 23 made rotatable by a supporting shaft 22 (FIG. 5) that iserected in a part of the annular frame 18. Therefore, the cloth frame 20can be moved and rotated by the supporter 23 and at the same time theannular frame 18 itself rotates to form polar co-ordinates.Consequently, the cloth frame can freely move and rotate in anydirection within the range of the annular frame. The pulse generator fordetecting the above mentioned three types of movements are unit 24 thatis operatively connected with the rotation of the supporting shaft 22,the unit 25 for the movement of the arm rod 21 and the unit 26 that isoperatively connected with the rotation of the annular frame 18.

An example of the rotary pulse generator that can be used in the abovementioned two embodiments shall be explained. A pulse generator shouldbe of the type that can generate a number of pulses that areproportional to the variation of the rotational angle caused therotation, that is to say, one that can convert the distance to a pulsenumber and generate pulses of signs respectively different depending onthe direction of the rotation. With reference to FIG. 6. a rotary slitplate 27 that is fitted in the pulse generator has slits 28 in the outerperipheral part and rotates while keeping a slight clearance between itand each of fixed slit plates 29a and 2% that have respectively slits31a and 3112. On one side of said rotary slit plate 27 are providedlamps La and Lb that are opposite to one another and on which arearranged respectively photoelectric elements 30a and 30b. When the slits28 of the rotary slit plate 27 coincide with the respective slits 31aand 31b of the fixed slit plates 29a and 29b, the lights from the lampsLa and Lb that fall upon the photoelectric elements 30a and 30brespectively generate electric powers. The slit plates 29a and 29b arefixed so as to have a phase difference of from each other.

When the rotary slit plate 27 rotates, the output curve that is shown inFIG. 7 is produced. The rotating directions of both outputs of thisphase difference of k 1r are judged or sensed with a known normal andreverse rotation judging or sensing circuit (FIG. 8). An output pulse isproduced at the output terminal on the upper side by normal rotation andat the output terminal on the lower side by reverse rotation. Both ofthese outputs are made pulses respectively in the positive and negativedirections by virtue of a composite circuit as shown on FIG. 9 and arerecorded in a magnetic tape 31 through a magnetic head 32. Therefore, incase the three pulse generators used in the above mentioned two clothframe moving devices generate positive or negative pulses that areproportional respectively to the two movements and rotation, such pulsesare recorded on turn in the magnetic tape.

The adjustment of the lateral amplitude of the lateral swing of theneedle of the zigzag embroidering sewing machine that is used in thepresent invention is made by the pushing of a lever with a knee.Therefore, a pulse generator to detect the amount of the movement of thelever is required. Thus four pulse generators including the three pulsegenerators of the cloth frame moving device are used. Therefore, thereare a total of four sets of the device shown in FIG. 9. Further, as fivetracks are provided on the magnetic tape 31, records can be properlymade on the tape.

Signals relating to the stopping and starting of the sewing machine arerecorded on another track. The in struction for automatically stoppingthe running of the tape when it is necessary to exchange the threadduring the operation thereof or when the operation is ended, is alsorecorded on this track. Signals such as three kinds of audiofrequencies, for example, 200, 1,000 and 7,000 Hz can be recorded onthis track. By the combination of these kinds, various required can beaccomplished. These three kinds (represented by A, B and C) of signalsthat are recorded on one track are separated by a filter circuit. Atable of such combinations is shown in the following wherein l showsthat the signal is recorded there.

com

The sewing machine stops.

The machine rotates at a slow rate.

The machine rotates at a fast rate.

The tape stops as the tape thread breaks.

The tape stops to change the tape thread.

(I. AU N'- frame moving devices of the embodiments shown either in FIGS.3 or 4 and 5 is made on a supporting table for a reproducing sewingmachine. Further, the respective rotary pulse generators of saidembodiments are replaced with pulse motors to drive the cloth framemoving device of the reproducing machine. When the magnetic tape 31 inwhich records have been made is fitted positioned in to the tape drivingdevice of the reproducing sewing machine, five magnetic heads 32a to 32ecome into contact with the tape as illustrated in FIG. 10. Among them,the magnetic heads 32a, 32b and 320 pick up the instructions magnetizedby the threepulse generators of the recording sewing machine and themagnetic head 32d picks up the lateral amplitude of the needle. Further,the magnetic head 32:: receives the starting and stopping instructionsfor the sewing machine. Therefore, the above mentioned mag netic heads32a to 32d drive the respective pulse motors 33a to 33d through anamplified pulse motor driving circuit. The magnetic head 32e starts andstops the reproducing sewing machine through an amplified starting andstopping control circuit. When the records in this magnetic tape 31 areto be reproduced, the cloth frame moving device is set in the sameposition as in the case of making the recorded tape of the recordingsewing machine and the machine is started, an embroidered design similarto the original figure can be reproduced. Thus, even an operator havinglittle or no knowledge embroidering experience can perform the operationrelatively easy.

Thus, in the conventional record carrier making method, thepoint-movement of the tracer has been performed manually. On the otherhand, according to the present invention, the cloth frame moving deviceprovides that the cloth frame is rotated in the X and Y axis directionsand the respective movements are detected by the rotary pulse generatorsfor use in a recording sewing machine The present invention, furtherprovides that the initial sheet be made by the same operation as that ofthe an ordinary embroidering operation and with this type of sewingmachine an operator having a high degree of skill in the field mayrecord, the program of of the X and Y axis directions and rotatingdirection of the cloth frame, the lateral amplitude of the needle andthe starting and stopping of the sewing machine as an original recordcarrier very easily within a short period of time by the utilization ofthe pulse generators. Therefore, not only such designs as in A, B and Cin FIG. 2 can be recorded but also any complicated figures can be veryquickly recorded. In producing the embroidery design, if the abovementioned record carrier is fed to a reproducing sewing machine, theoriginal embroidery design can be reproduced perfectly Thus, an improvedefficiency and a higher production will result.

Further, it is to be understood that the present invention can beapplied to the automation of not only embroidering but also to othersewing operations as well.

What is claimed is:

1. A method of making a record carrier for controlling an automaticembroidering sewing machine wherein an operator sews a selectedembroidery design with an automatic sewing machine having a sewingneedle comprising the steps of:

providing a cloth frame assembly having a stretched workpiece supportedthereon;

moving said cloth frame distance amounts in X-axis and Y-axis directionsand in an angular rotary di rection during the sewing of said design;

moving said needle by a distance amount in an X-axis direction duringthe sewing of said design;

detecting the distance amounts of the various movements of therespective cloth frame assembly and needle by the use of individualrotary pulse generators;

generating output pulses from said pulse generators,

which pulses represent said distance amounts;

recording said output pulses as master record trains in a magneticrecord carrier;

whereby said recorded record carrier may be played back to control anautomatic embroidering sewing machine to reproduce said design.

2. Apparatus for making a record carrier for controlling an automaticembroidering sewing machine wherein an operator sews a selectedembroidery design with an automatic embroidery sewing machine having asewing needle comprising in combination;

a first pair of rail members positioned parallel to each other andspaced from one another in the Y-axis plane;

a second pair of rail members positioned parallel to each other andspaced from one another in the X- axis plane;

individual rotary pulse generators connected with said first rail memberpair, said second rail member pair, and said cloth frame assembly,respectively;

each said pulse generators having a means to detect the amounts ofmovements on the respective X- axis and Y-axis planes and the amount ofthe variation of the rotation of said cloth frame assembly and a meansto generate output pulses which represent said amounts;

means connected to said pulse generators to record said output pulses ona magnetic record carrier,

whereby said recorded record carrier may be played back to control anautomatic embroidering sewing machine to reproduce said design.

' 'l ll l

1. A method of making a record carrier for controlling an automaticembroidering sewing machine wherein an operator sews a selectedembroidery design with an automatic sewing machine having a sewingneedle comprising the steps of: providing a cloth frame assembly havinga stretched workpiece supported thereon; moving said cloth framedistance amounts in X-axis and Y-axis directions and in an angularrotary direction during the sewing of said design; moving said needle bya distance amount in an X-axis direction during the sewing of saiddesign; detecting the distance amounts of the various movements of therespective cloth frame assembly and needle by the use of individualrotary pulse generators; generating output pulses from said pulsegenerators, which pulses represent said distance amounts; recording saidoutput pulses as master record trains in a magnetic record carrier;whereby said recorded record carrier may be played back to control anautomatic embroidering sewing machine to reproduce said design. 2.Apparatus for making a record carrier for controlling an automaticembroidering sewing machine wherein an operator sews a selectedembroidery design with an automatic embroidery sewing machine having asewing needle comprising in combination; a first pair of rail memberspositioned parallel to each other and spaced from one another in theY-axis plane; a second pair of rail members positioned parallel to eachother and spaced from one another in the X-axis plane; individual rotarypulse generators connected with said first rail member pair, said secondrail member pair, and said cloth frame assembly, respectively; each saidpulse generators having a means to detect the amounts of movements onthe respective X-axis and Y-axis planes and the amount of the variationof the rotation of said cloth frame assembly and a means to generateoutput pulses which represent said amounts; means connected to saidpulse generators to record said output pulses on a magnetic recordcarrier, whereby said recorded record carrier may be played back tocontrol an automatic embroidering sewing machine to reproduce saiddesign.